US20210348383A1 - Wall block, range of wall blocks, and formwork for producing a wall block - Google Patents

Wall block, range of wall blocks, and formwork for producing a wall block Download PDF

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Publication number
US20210348383A1
US20210348383A1 US17/285,061 US201917285061A US2021348383A1 US 20210348383 A1 US20210348383 A1 US 20210348383A1 US 201917285061 A US201917285061 A US 201917285061A US 2021348383 A1 US2021348383 A1 US 2021348383A1
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United States
Prior art keywords
wall
wall block
face
block
fin
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Granted
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US17/285,061
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US12054941B2 (en
Inventor
Oliver von Malm
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Start Somewhere Gemeinnutzige GmbH
Start Somewhere Gemeinnuetzige GmbH
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Start Somewhere Gemeinnutzige GmbH
Start Somewhere Gemeinnuetzige GmbH
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/20—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of concrete or other stone-like material, e.g. with reinforcements or tensioning members
    • E04C3/22—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of concrete or other stone-like material, e.g. with reinforcements or tensioning members built-up by elements jointed in line
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0002—Auxiliary parts or elements of the mould
    • B28B7/0014—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/02—Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
    • E04B2/16—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position
    • E04B2/18—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • E04B2002/0213—Non-undercut connections, e.g. tongue and groove connections of round shape
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • E04B2002/0215—Non-undercut connections, e.g. tongue and groove connections with separate protrusions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0256—Special features of building elements
    • E04B2002/0265—Building elements for making arcuate walls

Definitions

  • the invention relates to a wall block made of artificial stone material, having the following features:
  • the wall block has an overall elongate form with a longitudinal central axis and with a length that is greater than the width of the wall block, and the wall block comprises:
  • the wall block can additionally be formed having a fin at the transition between its second end face and its first wall surface side, and/or additionally at the transition between its second end face and its second wall surface side, which fin protrudes beyond a virtual flat surface located at the center of the second end face at a right angle to the longitudinal axis of the wall block.
  • Wall blocks are used so that it is possible to build walls therefrom in an expedient configuration.
  • Walls are three-dimensional structures which have a more or less great length (sometimes, when standing in front of the wall, it is said that the wall has a width of so-and-so many meters), a more or less great height, and a—not necessarily consistently constant—depth (which could also be referred to as “thickness” or “wall thickness”).
  • the construction is often such that the wall is formed by a plurality of rows, each consisting of wall blocks adjoining one another in the longitudinal direction of the wall, and a plurality of wall-block rows one on top of the other.
  • Wall blocks made of artificial stone material are known in all kinds of designs. Previously, only wall blocks were considered which were positioned adjoining one another in a substantially straight line in the longitudinal direction of the wall, and 90° corners of the wall could also be created. When considering the construction of walls having a 90° bend, either makeshift solutions with imperfect continuation of the wall at the point of the bend were used or special wall blocks having exactly one shape reflecting this bend were provided. In the case of wall bends, the known wall block designs have either yielded poor results or have left the user of the wall blocks with no flexibility. Wall blocks which allow the variable construction of walls having bends that deviate from 90° have previously not allowed the construction of walls having at least substantially continuously closed wall surface sides and having resistance against the penetration of wind and rain.
  • the problem addressed by the invention is that of providing a wall block made of artificial stone material which makes it possible for walls having selectable bends to be constructed as desired, there being good cohesion of adjacent wall blocks across the angle and the transitions from wall block to wall block in the rows of wall blocks, whether in the case of a bend or in the case of a straight wall portion, being functionally improved (appearance, stability, wall tightness).
  • the wall block according to the invention is made of artificial stone material, as specified in the first paragraph of the present application.
  • the wall block according to the invention has, on its first seating face, protruding extension arrangements; the first seating face could therefore also be referred to as the “male seating face” of the wall block.
  • the wall block according to the invention has, on its second seating face, internally accessible receiving arrangements; the second seating face could therefore also be referred to as the “female seating face” of the wall block.
  • the wall block can be inserted in a wall such that its first seating face faces upward and its second seating face faces downward (“male is at the top”), or alternatively inserted such that its second seating face faces upward and its first seating face faces downward (“female is at the top”). In most cases, the relevant orientation of these two orientations remains the same at least for a portion of the wall, as will become clearer below in the embodiments.
  • the wall block does not necessarily have to be designed such that the above-mentioned hindrance of the relative movement in all conceivable directions in the “horizontal plane” of engagement is prevented. It is possible to design the wall block such that said prevention of the relative movement takes effect only for part of the total conceivable relative movement directions over 360°.
  • vertical direction refers to the direction that results when progressing from one wall block to the next wall block positioned above or below.
  • horizontal direction refers to the direction that results when moving in the direction of the flush longitudinal central axes of the wall blocks in a row of wall blocks.
  • the wall block according to the invention can be designed such that it is possible to place two wall blocks one on top of the other free of joining material (e.g. mortar) therebetween and still have the required force transmission capacity “in the vertical direction” and “in the horizontal direction.”
  • the form-fitting engagement between the extension arrangement and the receiving arrangement not only fulfils a purpose in the force transmission in the horizontal direction, but is also a good positioning aid for the person constructing a wall out of wall blocks.
  • the wall block placed on top is already substantially correctly placed on the lower wall block due to the form-fitting engagement.
  • this statement does not exclude the possibility of placing or positioning the wall blocks according to the invention on top of one another with joining material (e.g. mortar) therebetween. In this case, the cohesion of the two wall blocks involved is more extensive and the wall is tight against wind and water. On the other hand, an existing wall can no longer be easily dismantled.
  • adjacent wall blocks are positioned “close together,” although this does not mean immediate mutual contact in the horizontal direction due to the manufacturing tolerances mentioned above. This is possible, but not absolutely necessary.
  • reference is made in this application to a further wall block being positioned above or below a wall block under consideration this is not intended to mean that the further wall block is substantially the same continuation of the wall block under consideration.
  • Wall blocks designed in this way require less artificial stone material, are lighter and are advantageous with regard to thermal insulation. Further advantages will become clear below.
  • the wall block according to the invention can be designed in terms of weight and size such that it can be carried and placed or positioned by a person. It is possible to design the wall block according to the invention having a central floor which extends substantially parallel to the seating face of the wall block. This floor can be continuous as a whole (in which case the wall block has no continuous passage), but it can also have one or more openings.
  • each extension arrangement has such a design of its outer face facing outward away from the center of the extension arrangement and each receiving arrangement has such a design of its inner face facing inward toward the center of the receiving arrangement that continuous arched, form-fitting engagement or interrupted arched, form-fitting engagement with the complementary receiving arrangement and extension arrangement, respectively, of the third further or fourth further wall block is possible.
  • Interrupted arched, form-fitting engagement means that the engagement surface of the relevant extension arrangement and/or the relevant receiving arrangement is not continuous, but has gaps or interruptions.
  • an extension arrangement which, viewed as a whole, extends over an angular range of 180° can be divided into three parts each having an angular range of 50°, and two interruptions each having an angular range of 15°.
  • interruption recesses are also possible in the engagement surface of the receiving arrangement. In this context, it is functionally essential to be able to place an arched envelope line in the extension arrangement or the receiving arrangement.
  • the design for arched form-fitting engagement extends over an angular range having a size of at least 180° and at most 360°. “At least 180° ” provides favorable conditions for good engagement of adjacent wall blocks. If it is desired to implement with much more than 180°, this requires consideration in the other wall block design for wall blocks having continuous passages from the first seating face to the second seating face. Angular ranges that are slightly greater than 180°, in particular that have a size between 180° and 200°, are very advantageous.
  • the design of the wall block according to the previous paragraph makes a great variability in the construction of walls accessible.
  • the wording “spacing of the two centers which substantially corresponds to half the length of the wall block” in practice amounts to the spacing of the two centers being slightly greater than half the length of the wall block, so that in the case of two wall blocks positioned adjacently in the longitudinal direction—in the sense of negative production tolerance—a little free space remains if, in the row of wall blocks above or the row of wall blocks below, the wall blocks are placed with a longitudinal offset with respect to the row of wall blocks under consideration.
  • the term “centers” is to be understood to mean that an expedient center for the extension arrangement or the receiving arrangement, as seen in plan view of the first seating face or the second seating face, is considered.
  • the above-mentioned fin(s) increase(s) the stability of walls constructed using such wall blocks against forces acting against the first wall surface side or against the second wall surface side, e.g. wind forces or impact forces.
  • the tightness of the wall against wind and rain is also improved.
  • this also results in a smoother appearance of the first wall surface side and/or of the second wall surface side.
  • these recesses make it easier to connect a first further wall block and/or a second further wall block with angles between the longitudinal central axes.
  • the first end face and/or the second end face can be designed—in plan view of the first seating face or the second seating face—to be outwardly convex and semicircularly rounded, with the exception of the region or regions where an above-mentioned fin protrudes.
  • This design increases the tightness of a wall constructed using wall blocks according to the invention and the stability of the wall against forces against the first or second wall surface side.
  • a maximum angle that is slightly smaller than 90° is possible.
  • a maximum angle having a value in the range of from 25° to 50° is possible.
  • the above-mentioned pocket can be, but does not need to be, filled with pourable material after the relevant wall block or a larger number of wall blocks has/have been placed. Further details follow below.
  • Such a wall block has a good compromise between strength, low material use and great utilization of the seating surface despite the extension arrangements and receiving arrangements.
  • the two straight portions of the peripheral wall each have a greater wall strength in their central regions than the wall strength of the peripheral wall in the rounded portions; and that, on the first seating face, the first seating surface is widened in each case in the region of the relevant above-mentioned central region toward the inside of the wall block, beyond the above-mentioned greater wall thickness. This increases the stability of the wall block, especially in the central region of the wall block, which is particularly useful for this purpose.
  • pourable material can be introduced into the interior of the wall block on the end plate.
  • adjacent wall blocks in the longitudinal direction of the wall block can be linked in order to increase the force transmission capacity.
  • the invention also provides a wall block which can have one or more of the further features disclosed above and which is additionally wider in the region of its first end face than in the region of its second end face.
  • a wall block makes it possible to conveniently produce a transition between a wall region of greater wall thickness and a region of smaller wall thickness.
  • artificial stone material for the wall block many materials can be considered which can be brought into the shape of the wall block in a first, forming state, and which subsequently—usually after a hardening process—retain the shape of the wall block with the required strength.
  • Specific materials under consideration include compacted clay, geopolymers, sand-lime bricks, bricks and—as already mentioned above as a prominent material—concrete.
  • the desired strength can be varied in particular by varying the cement amount and selecting the grain size of the sand or gravel.
  • the wall block mentioned in this paragraph is particularly suitable for use in combination with the disclosed wall block having an elongate form.
  • the wall block according to the invention can be used to construct many types of walls or partitions, the words “wall” and “(walled) partition” being synonymous and the term “wall” in the present application also being intended to include “partitions.”
  • Typical examples of walls that can be constructed using the wall block according to the invention are walls of buildings (exterior walls and interior walls), division walls, supporting walls, decorative walls, boundary walls, parapet walls, etc. The use thereof for house walls (exterior walls or interior walls) is cited as particularly prominent.
  • the simple producibility of the wall block according to the invention, even without an industrialized environment, and the extremely simple and rapid construction of walls using wall blocks according to the invention are very advantageous, very particularly in less industrialized environments, in connection with natural disasters and in connection with situations where it is desirable to create solid housing for a large number of people using simple means and as quickly as possible.
  • the invention further relates to a wall block family containing at least the 14 wall block types listed in the following:
  • (g1) wall block which is designed as specified under (aa), (bb) and (dd) for wall block type (al) and which has a substantially corresponding length and width and is free of one or more fins;
  • wall block types are explained in the following in the example part with reference to drawings.
  • the wall block types (a2) to (g2) can be designed as has been disclosed above for the wall block according to the invention, i.e. can have one or more of the features disclosed above.
  • the invention also relates to an assortment of wall blocks which contains wall blocks of at least two different wall block types from the above list (a1) to (g2), but which can also contain other wall block types.
  • the assortment of wall blocks comprises wall blocks at least of the wall block types (a2), (b2) and (c2).
  • the invention also relates to a wall, characterized in that it has at least one portion in which wall blocks are installed, as disclosed above as wall blocks according to the invention.
  • the wall according to the invention can have at least one portion in which claimed wall blocks having at least one passage in each case are present and pockets are present between adjacent end faces of adjacent wall blocks, which passages and/or pockets are filled with material that was pourable in the filling state.
  • a variety of pourable materials can be considered, although a distinction can initially be made between materials that set permanently after filling and materials that do not set substantially permanently after filling.
  • walls made of wall blocks according to the invention can be easily dismantled and the dismantled wall blocks can be used to construct new walls.
  • the above-mentioned filling stabilizes the wall and increases its mass, heat storage capacity, thermal insulation and sound insulation.
  • the pourable material can be, but does not need to be, filled in over the entire wall. Filling primarily at wall regions where there are increased requirements for strength is possible. Concrete is cited as a typical material that sets. Typical materials that do not solidify significantly are soil, clay, sand and gravel. Since the passages and the pockets, in many cases alternating with one another, usually extend from top to bottom in the wall, at least for a plurality of wall block heights, it is easy to set reinforcing bars in the passages and/or pockets and thus arrive at vertical reinforced concrete cores of the wall.
  • the wall according to the invention which can have one or more of the features disclosed above, can also be characterized in that it has at least one bend in its longitudinal extension direction, which bend is formed by means of the above-mentioned variable-angle form-fitting engagement of an extension arrangement and a receiving arrangement.
  • bends it is possible to easily produce in particular wall corners of external building walls and wall corners of internal building walls. These corners often have an angle of approximately 90°, although they can also have other angles, as will become clearer below.
  • One possibility that is particularly worth mentioning is to construct an external wall of a house having one or more bends which are mostly within the range of 0° to 45°, in order to follow a non-straight course of a property boundary and thus make optimal use of the property area.
  • the wall according to the invention which can have one or more of the features disclosed above, can further have at least one T-cross connection and/or at least one X-cross connection.
  • the wall blocks according to the invention make it possible to produce such connections in a very simple manner, as will become clearer below.
  • the wall according to the invention which can have one or more of the features disclosed above, can further have at least one lintel over a wall opening and/or at least one wall anchor extending along the wall, the lintel or the wall anchor containing claimed wall blocks according to the invention filled with concrete. It is particularly favorable for such a wall to use wall blocks that have an integrally formed end plate or a separately inserted end plate, so that concrete can be filled into the relevant wall blocks and does not continue to run away downwards.
  • reinforced concrete i.e. the insertion of reinforcing bars—usually extending horizontally—in the wall blocks, is advantageous.
  • the wall according to the invention which has one or more of the features disclosed above, can further have at least one portion in which claimed wall blocks are placed one on top of the other free of joining material therebetween.
  • blocks or bricks are placed one next to the other in a first, lowermost row, specifically with mortar being introduced between two horizontally adjacent bricks.
  • a second row of bricks is then placed thereon, with a mortar layer being applied between the first row and the second row.
  • the mortar after hardening, produces a strong bond between two adjacent bricks, giving the wall the required strength.
  • wall blocks according to the invention it is an extraordinarily advantageous property of wall blocks according to the invention that the form-fitting engagement between extension arrangements and receiving arrangements, as well as one or more fins on each of the wall blocks, creates such a high force transmission capacity between adjacent wall blocks that in many cases it is possible to erect walls in which the wall blocks are positioned free of joining material therebetween. This does not affect the possibility of working with mortar at locations at which higher forces are applied to the wall.
  • the wall blocks according to the invention can be used to construct walls that meet the “Eurocode 6” standard, which refers to wall strength, even without the mortared joints between the wall blocks.
  • the invention also relates to a formwork or mold for producing wall blocks according to the invention which have one or more of the features disclosed above, which formwork is characterized in that
  • the formwork is composed of a plurality of formwork parts which can be disassembled in a simple manner also makes it possible to produce a modified formwork very simply by leaving out and/or adding and/or exchanging individual formwork parts and thus to produce wall blocks having different geometries. This will become clearer below in the embodiments.
  • formwork parts or all of the formwork parts can be inexpensively made of plastics material; alternatively, formwork parts made of metal are possible.
  • FIG. 1 is a perspective view of a block which, however, does not have a fin/fins, for reasons of clearer and more concise description;
  • FIG. 2 is a plan view of the first seating face of the block of FIG. 1 ;
  • FIG. 3 is a plan view of the opposite second seating face of the block of FIG. 1 ;
  • FIGS. 4 to 9 show six further embodiments of a block, in each case in plan view of the first seating face;
  • FIG. 10 shows two blocks of FIG. 6 , placed against one another end face to end face, in a plan view of the first seating faces;
  • FIG. 11 is a perspective view of three blocks of FIG. 6 , consisting of two blocks in a lower row of blocks and one block of a second row of blocks placed on top;
  • FIG. 12 shows the block arrangement of FIG. 11 in a plan view of the first seating faces of the blocks
  • FIG. 13 shows the arrangement of the blocks of FIG. 11 in a longitudinal section along C-C in FIG. 12 ;
  • FIG. 14 shows the arrangement of the blocks of FIG. 11 in a cross-section along D-D in FIG. 12 ;
  • FIG. 15 is a perspective view of an arrangement of seven blocks according to FIG. 6 , of which four blocks are in a lower, first row of blocks and three blocks are in a second row of blocks placed thereon;
  • FIG. 16 is a perspective view of the blocks of FIG. 15 , but now with the rows of blocks bent several times;
  • FIG. 17 is a perspective view of an arrangement of nine blocks, specifically five blocks in a lower, first row of blocks and four blocks in a second row of blocks placed thereon;
  • FIG. 18 is a perspective view of a detail of an X-cross of a wall
  • FIGS. 19 to 25 show seven further embodiments of a block, in each case in plan view of the first seating face;
  • FIG. 26 is a perspective view of a detail of a wall which is erected using blocks according to a further embodiment
  • FIG. 27 is a plan view of the wall detail of FIG. 26 ;
  • FIG. 28 is a longitudinal section of the wall detail of FIG. 26 ;
  • FIG. 29 is a perspective view of a further embodiment of a block
  • FIG. 30 is a plan view of the block of FIG. 29 ;
  • FIG. 31 shows the block of FIGS. 29 and 30 in a longitudinal section along J-J in FIG. 30 ;
  • FIG. 32 shows the block of FIGS. 29 and 30 in a cross-section along K-K in FIG. 30 ;
  • FIG. 33 is a perspective view of a detail of a wall which has been erected using blocks according to the invention.
  • FIG. 34 is a perspective view of a detail of a wall which has been erected using blocks according to the invention.
  • FIG. 35 is a perspective exploded view of a formwork for producing a block according to the invention, the formwork parts that form the second seating face of the wall block being closer to the viewer;
  • FIG. 36 is a perspective exploded view of the formwork of FIG. 35 , the formwork parts that form the first seating face of the wall block with the extension arrangements being closer to the viewer;
  • FIG. 37 is a section of the formwork of FIG. 35 in a plane which is approximately midway between the first and second seating faces in the produced wall block;
  • FIG. 38 is a perspective view of the formwork of FIG. 35 in the clamped state.
  • the longitudinal central axis L is shown, which extends at half the width b and half the height h (measured between a first seating surface 4 and a second seating surface 6 ).
  • the outer contour or lateral surface 8 of the block 2 is composed—as seen in the plan views of FIGS. 2 and 3 —of two semicircles at the block ends and two straight sections therebetween.
  • the side of the block 2 facing upward in FIG. 1 is its first seating face 10
  • the side of the block 2 facing downward in FIG. 1 is its second seating face 12 .
  • the side of the block 2 (upper semicircle) facing upward in FIG. 2 is its first end face 14
  • the side of the block 2 (semicircle) facing downward in FIG. 2 is its second end face 16 .
  • the side of the block 2 (straight section) facing left in FIG. 2 is its first wall surface side 18
  • the side of the wall block 2 (straight section) facing right in FIG. 2 is its second wall surface side 20 .
  • the block 2 In the positioning of the block 2 as shown in FIG. 1 , its first seating face 10 faces upward and is thus the upper face of the block 2 in the insertion state. In the positioning shown in FIG. 1 , the second seating face 12 of the block 2 faces downward, i.e. is the lower face thereof in the insertion state. It is emphasized that the block 2 can alternatively and easily be used “the other way around,” i.e. the first seating face 10 as the lower face and the second seating face 12 as the upper face.
  • the end faces 14 and 16 of the block 2 are intended to each face an end face 14 or 16 of an adjacent block 2 when the block 2 is in the insertion state.
  • explanations below will show that there are usage situations in which the end faces 14 and 16 are not adjacent to end faces 14 and 16 , respectively, of other blocks 2 .
  • first wall surface sides 18 are all part of a first wall surface.
  • second wall surface sides 20 are part of an opposing second wall surface.
  • the block 2 On its first seating face 10 , the block 2 has two extension arrangements 30 arranged in a row in the longitudinal direction of the block 2 ; see FIGS. 1 and 2 . On its second seating face 12 , the block 2 has two receiving arrangements 40 arranged in a row along the length of the block 2 ; see FIG. 3 .
  • Each extension arrangement 30 is an arched rib which extends over an angular range of approximately 200° and protrudes beyond the remaining first seating face 4 in the height direction.
  • Each receiving arrangement 40 is formed by an arched surface which extends over an angular range of approximately 200° and, for a partial angular range of 180°, extends parallel to the arc of the relevant end face 14 or 16 .
  • Each of the extension arrangements 30 is complementary to each of the receiving arrangements 40 , i.e. form-fittingly fits into one of the receiving arrangements 40 when a block 2 , with its second seating face 12 facing downward, is placed on top of the block 2 of FIG. 1 , whether this be without a longitudinal offset of these two blocks 2 or whether this be with a longitudinal offset of these two blocks 2 by a half block length l.
  • the terms “complementary” and “form-fitting” are to be understood as functionally appropriate given the production tolerances that are common in the field of wall blocks.
  • the outward facing outer periphery of the arc of the relevant extension arrangement 30 has a slightly smaller radius than the radius of the inward facing arc surface of the relevant receiving arrangement 40 , such that the extension arrangement 30 and the receiving arrangement 40 can fit inside one another easily.
  • the reference sign 32 refers—as seen in the plan views of FIGS. 2 and 3 —to the center of the relevant extension arrangement; the reference sign 42 refers to the center of the relevant receiving arrangement 40 .
  • the centers 32 and 42 each lie on a common line (central axis) which extends in the direction of the height h of the block 2 and intersects the longitudinal central axis L.
  • the block 2 of FIGS. 1 to 3 is a hollow block which has a peripheral outer wall 50 and—delimited by the wall 50 —a passage 52 which extends from the first seating face 10 to the second seating face 12 .
  • the block 2 can have a plurality of passages instead of the single passage 52 , which passages each extend from the first seating face 10 to the second seating face 12 , e.g. two circular passages having the centers 32 and 42 , respectively, and a central connecting part between the two wall regions on the two wall surface sides 18 and 20 .
  • the block 2 can alternatively be designed as a full block without one or more passages 52 .
  • the receiving arrangements 40 would be formed, for example, as circular 360° recesses in the second seating face 12
  • the extension arrangements 30 would be formed, for example, as circular 360° ribs on the first seating face 4 .
  • the regions on the first seating face 10 of the block 2 where there is no extension arrangement 30 and no passage 52 are collectively referred to as the first seating surface 4 of the block 2 .
  • the regions on the second seating face 12 of the block where there is no receiving arrangement 40 and no passage 52 are collectively referred to as the second seating surface 6 of the block 2 . If a third further block 2 , with its second seating face 12 facing downward, is placed on top of the block 2 of FIG.
  • the extension arrangements 30 are each designed with a height and the receiving arrangements 40 are each designed with a height dimension such that the described form-fitting engagement between the relevant extension arrangement 30 and the relevant receiving arrangement 40 takes place despite the interposed mortar.
  • the length l of the block 2 is measured from the center of the first end face 14 to the center of the first end face 16 .
  • the width b of the block 2 is measured between the center of the first wall surface side 18 and the center of the second wall surface side 20 .
  • the outer lateral surface is not at a right angle to the first seating surface 22 and the second seating surface 24 , the length l and the width b are measured at the largest point in each case.
  • the height h of the block 2 is measured from the first seating surface 4 to the second seating surface 6 .
  • 1 to 3 has a spacing between the two centers 32 or between the two centers 42 of 250 mm, a length l of 495 mm, a width b of 245 mm, and a height h of 175 mm.
  • Said real length and said real width are slightly smaller than the nominal length of 500 mm and the nominal width of 250 mm, in order to be able to work easily in light of the production tolerances when joining blocks 2 .
  • the block 2 is twice as long as it is wide and the spacing of the two centers 32 or the two centers 42 is half as large as the block length. Considering the real dimensions, this statement applies with “substantially.”
  • the block 2 of FIGS. 1 to 3 is mirror-symmetrical with respect to its longitudinal central plane and is mirror-symmetrical with respect to its transverse central plane.
  • the block 2 can alternatively have a length l that is significantly greater than twice the width b.
  • the block 2 can alternatively have more than two extension arrangements 30 and more than two receiving arrangements 40 , in a row in each case.
  • Blocks 2 which have two extension arrangements 30 and two receiving arrangements 40 and a length l that substantially corresponds to twice the spacing of the two centers 32 or the two centers 42 , can nevertheless be used in a particularly favorable and varied manner in the construction of walls.
  • the width b can certainly be slightly larger or slightly smaller than half the block length l.
  • the first wall surface and the second wall surface are surfaces which are closed as a whole and pass through in an almost completely planar manner.
  • each extension arrangement 30 and each receiving arrangement 40 extend over an angular range of more than 180°, the mentioned form-fitting engagement between a relevant extension arrangement 30 and a relevant receiving arrangement 40 is effective not only against forces acting transversely to the wall, but also against forces acting in both longitudinal directions of the wall (highly tensile clamping in the longitudinal direction of the wall).
  • said form-fitting engagement is no longer effective in all horizontal directions, but is effective in some of the horizontal directions.
  • the second seating face 6 is composed substantially of two semicircular strips 26 on the outside along the receiving arrangements 40 and two substantially straight strips 28 therebetween.
  • the straight strips 28 measured in the direction of the width b—have a greater width than the semicircular strips 26 .
  • the cross-sectional area of the passage 52 progressively decreases slightly, and this sloping allows the separation of the block 2 from the formwork by means of which it has been produced.
  • the passage 52 has a greater slope 34 all round toward the interior of the passage 52 .
  • the extent of this greater slope 34 is selected such that the width of the two substantially semicircular strips 36 of the first seating surface 4 is substantially equal to the width of the semicircular strips 26 on the second seating surface 6 .
  • the straight strips 38 of the first seating surface 4 are wider between the ends of the two extension arrangements 30 —measured in the width direction of the block 2 —than the straight strips 28 on the second seating surface 6 . This increases the stability of the block 2 and produces a better connection of the four end regions 44 of the two extension arrangements 30 to the wall 50 of the block 2 .
  • each of the extension arrangements 30 could be formed as a continuous arched rib, for example a plurality of segments of a rib could be provided so as to provide interrupted arched form-fitting engagement with the relevant receiving arrangement 40 . Functionally, there would then be a kind of arched envelope along the parts of the relevant rib.
  • FIGS. 4 to 9 show further embodiments of blocks 2 according to the invention, which can be understood most clearly as modifications of the block 2 of FIGS. 1 to 3 by providing fins 60 .
  • the block 2 has a single fin 60 located at the transition between the first end face 14 and the first wall surface side 18 .
  • the main extension direction of the fin 60 is from bottom to top in FIG. 4 , such that the outer surface 62 of the fin 60 continues the first wall surface side 18 of the block 2 .
  • the inner surface 70 of the fin 60 is composed of the following portions in this order: an outwardly concave rounding 68 , a straight portion 71 parallel to the outer surface 62 of the fin 60 , an outwardly convex transition portion 73 , and an outwardly concave rounded portion 72 .
  • This portion 72 is part of a virtual semicircle which extends at a narrow spacing parallel to a fin-free first end face 14 of an adjacently placed block 2 .
  • the fin 60 then ends with a relatively small dimension between the outer face 62 and the inner face 70 .
  • the radius of the outwardly convex rounding 72 is substantially as great as the radius of the rounded portion on the end faces 14 and 16 .
  • the outwardly concave rounding 68 near the root 64 of the fin 60 has a significantly smaller radius.
  • the width of the fins between their outer face 62 and the part of their inner face 70 that is parallel to their outer face 62 is slightly smaller than the width of the straight portion 38 of the first seating surface 22 .
  • the extent v of protrusion of the fin 60 beyond a virtual flat surface 61 which is located at the center of the first end face 14 at a right angle to the longitudinal central axis L, is smaller than the spacing between the center of the first end face 14 and the center 32 of the extension arrangement 30 which is nearest to the fin 60 and is at the top in FIG. 4 .
  • the extent of protrusion v is approximately half the last-mentioned spacing.
  • FIGS. 4 to 9 each show a vector 58 which extends on the longitudinal central axis L of the relevant block 2 and, from the center of the block, is directed away from the block 2 .
  • the fin 60 extends in parallel on the left to the vector 58 .
  • the block 2 of FIG. 5 differs from the block 2 of FIG. 4 in that it has a single fin 60 , but now in mirror inversion at the other transition between the first end face 14 and the second wall surface side 20 .
  • the fin 60 extends in parallel on the right to the vector 58 .
  • the block 2 of FIG. 6 has exactly two fins 60 on its second end face 16 , in each case at the transition to the first wall surface side 18 and the second wall surface side 20 , respectively.
  • the fins 60 extend in parallel to one another and parallel on the left and parallel on the right to the vector 58 .
  • the block 2 of FIG. 7 has exactly three fins 60 , one as in the block 2 of FIG. 4 and two as in the block of FIG. 6 .
  • the block 2 of FIG. 8 has exactly three fins 60 , one as in the block of FIG. 5 and two as in the block of FIG. 6 .
  • the block 2 of FIG. 9 has exactly four fins 60 , two protruding downward in FIG. 9 as in FIG. 6 and two protruding upward in mirror inversion in FIG. 9 .
  • the fins 60 have the same design (although mirror-inverted in some cases) and the same dimensions.
  • the statements made on the design and dimensions of the fin 60 in connection with FIG. 4 also apply analogously to FIGS. 5 to 9 .
  • FIG. 10 two blocks 2 , each having a first end face 14 with two fins 60 and an overall semicircularly rounded second end face 18 , are placed one on top of the other.
  • FIG. 10 shows that the geometry of the fins 60 makes it possible for the block 2 u positioned at the bottom in FIG. 10 to be pivoted relative to the further block 2 o shown at the top of FIG.
  • FIG. 10 The same applies if a fourth further block 2 is placed below the shown blocks 2 o and 2 u, the extension arrangements 30 of which further block are in form-fitting engagement with two receiving arrangements 40 of the blocks 20 and 2 u.
  • FIG. 10 clearly shows that the extent of protrusion v of the fins 60 determines the magnitude of the pivot angle 81 that is maximally possible before the described gap between the two adjacent blocks 2 is formed. The shorter the fins 60 , the greater the maximum pivot angle. It can also be clearly seen in FIG. 10 that the maximum pivot angle 81 even exceeds 90° (in this case specifically approximately 100°) if the upper block 2 o is formed without the fin 60 on the left in FIG. 10 .
  • FIG. 10 also shows that the shape of the fins 60 described in detail in connection with FIG. 4 represents a recess of the first end face 14 of the block 2 toward the block 2 in comparison with a virtual arc 74 , which is shown in FIG. 5 for illustrative purposes.
  • This virtual arc 74 begins in the center of the first end face 14 and extends to the end 66 of the relevant fin 60 .
  • Due to being set back as described, in FIG. 10 a pocket 76 is created next to each fin 60 between the upper block 2 o and the lower block 2 u. The advantages of the pockets 76 are explained in more detail below.
  • FIGS. 11 to 14 show an arrangement of three blocks 2 , specifically two blocks 2 as part of a lower row of blocks end face to end face and a further block as part of a second row of blocks placed thereon.
  • the last-mentioned block 2 is placed with a longitudinal offset by half a block length l and thus links the two blocks 2 of the lower row of blocks.
  • All three blocks 2 are blocks 2 according to FIG. 6 or FIG. 10 , i.e. having two fins 60 on the first end face 14 in each case and an overall semicircularly rounded second end face 16 .
  • the fins 60 are oriented in the same direction in all the blocks 2 , i.e. are directed to the upper left in FIG. 11 and to the left in FIG. 12 .
  • FIGS. 13 and 14 show very clearly what has already been described above in connection with FIGS. 1 to 3 .
  • the two adjacent extension arrangements 30 of the two lower blocks 2 sit form-fittingly in the two receiving arrangements 40 of the upper block 2 .
  • the left, lower block 2 can be pivoted relative to the right, lower block 2 and thus also relative to the upper block 2 at most by a relatively small angle (between the longitudinal central axes L of the right, lower block and the upper block 2 on the one hand and the longitudinal central axes L of the left, lower block 2 on the other hand).
  • the maximum pivotability is achieved when an end region of the left extension arrangement 30 , visible in FIG. 12 , of the left, lower block 2 abuts one of the two fins 60 of the upper block 2 .
  • FIG. 11 also shows that due to the fins 60 , the gaps 80 between two adjacent blocks 2 in the row of blocks are much smaller than for blocks 2 without fins 60 .
  • the blocks 2 of the first, lower row of blocks 82 are oriented with their fins 60 in a first direction (toward the top left in FIG. 15 ), whereas the blocks 2 in the second row of blocks 84 placed thereon are all oriented in the opposite direction (toward the bottom right in FIG. 15 ).
  • FIG. 16 demonstrates that, despite the fact that each block 2 of the upper row of blocks 84 links two blocks 2 of the lower row of blocks 82 , walls 85 can be constructed with one or more bends 77 in the longitudinal direction thereof.
  • bends 77 are possible where extension arrangements 30 and receiving arrangements 40 are in form-fitting engagement with one another adjacent to end faces 14 and 16 , respectively, without fins 60 there.
  • attention is drawn to the right (second) end face 16 of the leftmost block 2 in the lower row 82 of blocks and the left (second) end face 16 of the leftmost block 2 in the upper row 84 of blocks in FIG. 16 .
  • the relevant block ends of the two blocks 2 involved there are free of fins 60 .
  • Bends 77 are possible in both pivoting directions.
  • the bend 77 in the longitudinal extension direction of the wall 85 is limited to slightly more than 45° as a maximum value, as described with reference to FIG. 10 .
  • FIG. 16 As a total of eight wall bends by 45°, all in the same pivot direction, the result is an annularly closed wall polygon.
  • blocks 2 according to FIG. 4 i.e. having only one fin 60
  • blocks 2 according to FIG. 5 i.e. having only one fin 60
  • annular closed wall polygons having six corners (angled by 60°) or having four corners (angled by 90°).
  • the described wall polygons can be used as a type of column. It is even possible to completely fill the interior of the polygon with pourable material, in particular concrete, in order to construct a column.
  • the wall polygon thus serves as a kind of formwork for this column.
  • walls can also be constructed from two parallel wall block row stacks placed closely together.
  • links can be created between the two wall block row stacks using connecting blocks placed at right angles to the wall face sides.
  • FIG. 17 shows how the blocks 2 according to the invention can be used to construct a wall corner 86 between two wall portions when the measured inner angle of the wall corner 86 is smaller than approximately 135°.
  • the interior angler corner has an internal angle of 90° in the case shown. However, even internal angles that are slightly smaller than 90° are possible.
  • FIG. 18 shows an X-cross 88 of two walls which can be made using blocks 2 disclosed in this application.
  • a block 2 c according to FIG. 22 is inserted immediately to the lower right of the X-cross 88 .
  • the lower half of FIG. 18 is a hatched illustration of the four blocks 2 which are involved in connecting the wall portion to the center of the X-cross 88 .
  • FIG. 18 can be easily reconfigured into a T-cross of three wall portions. In this case, for example, the wall portion extending away to the upper right is not present. Instead of the lowermost integration block 2 in the lower part of FIG. 18 , a block 2 is inserted there that does not extend out of the T-cross to the top right.
  • FIGS. 19 to 25 show seven embodiments of blocks 2 which, which respect to the absence of a fin 60 or with respect to the presence of a fin 60 or a plurality of fins 60 , are constructed as shown in FIGS. 1 to 3 and 4 to 9 , although now for blocks 2 which have only exactly one extension arrangement 30 and one receiving arrangement 40 and in which the length l is equal to the width b.
  • the single extension arrangement 30 and the single receiving arrangement 40 are each circular over 360°.
  • the seven blocks 2 of FIGS. 19 to 25 correspond to the wall block types (g1) and (a1) to (f1), as discussed in the general part of the description.
  • the seven blocks 2 of FIGS. 1 to 3 and 4 to 9 correspond to the wall block types (g2) and (a2) to (f2), as discussed in the general part of the description.
  • the seven blocks 2 of FIGS. 1 to 3 and 4 to 9 on the one hand and the seven blocks 2 of FIGS. 19 to 25 on the other hand belong to a wall block family, as discussed in the general part of the description.
  • FIG. 26 shows blocks 2 which are blocks 2 according to FIG. 6 in terms of basic design, but have an opening 90 in each of the two end faces 14 and 16 that is delimited all around.
  • Dotted lines 92 indicate vertical reinforcing bars 92 and dotted lines 94 indicate horizontal reinforcing bars 94 .
  • the horizontal reinforcing bars 94 each extend in the longitudinal direction through a plurality of blocks 2 and the openings 90 thereof.
  • the vertical reinforcing bars 92 extend vertically through a plurality of block levels, specifically into the interiors of the extension arrangements 30 and the receiving arrangements 40 and into the pockets 76 . Since there is a passage 52 below each pocket 76 and above each pocket 76 in the next block level, the vertical reinforcing bars 92 can pass through a greater number of block levels without complication.
  • the horizontal reinforcing bars 94 are most expediently inserted gradually, following the progress of the construction of the wall. Lateral “threading” of the blocks 2 on ready-placed horizontal reinforcing bars 94 is also possible.
  • the previous paragraphs have consistently referred to filling with concrete; however, it is emphasized that other pourable materials, as have been disclosed in the general part of the description, can be used instead of concrete.
  • the reinforcing bars disclosed are usually structural steel bars of the type commonly used for constructing structures made of concrete.
  • FIG. 29 shows a block 2 which has openings 96 in its two end faces 14 and 16 that are open toward its second seating face 6 and which is provided near its first seating face 4 with an integrally formed end plate or a separately inserted end plate 98 , e.g. made of concrete or stone or metal or plastics material.
  • the end plate 98 can be easily inserted, since the passage 52 decreases in its inner surface area as it approaches the first seating face 4 , as can be clearly seen in FIGS. 31 and 32 .
  • FIG. 33 shows a further area of application of blocks 2 of the type shown in FIGS. 29 to 32 .
  • FIG. 33 shows a corner anchor 102 which extends from one wall corner 86 consisting of a plurality of block lengths to one side and to the other side, thus stabilizing the wall corner 86 .
  • an opening 96 must be provided asymmetrically at the transition of an end face 14 or 16 into one of the wall surface sides 18 or 20 , so that the corner anchor 102 forms a continuous corner concrete beam here.
  • the corner anchor 102 can be expanded to form an annular anchor which extends e.g. around the upper edge of an external building wall.
  • FIGS. 29 to 34 show that in the uppermost block level, where the concrete fillings are introduced, the blocks 2 must be positioned with their first seating face 4 (where the extension arrangements 10 are located) facing downward. This can be achieved by positioning the blocks, from the first, lowermost block level upward, with the first seating face 4 facing downward. Another possibility is to work with blocks 2 at the second highest block level, for example, which, as special blocks, do not have any extension arrangements 10 , but only receiving arrangements 40 on both seating faces 4 and 6 .
  • FIGS. 35 to 38 show a formwork 110 or a mold 110 by means of which blocks 2 according to the invention of different designs can be produced.
  • pourable concrete is poured into the mold 110 via an opening 112 .
  • the mold 110 is opened and the block 2 is removed.
  • the formwork 110 has the following formwork parts:
  • FIGS. 35 to 38 For details on the design of the above-mentioned formwork parts, reference is expressly made to FIGS. 35 to 38 .
  • the formwork part 114 has the shape of a semicircular ring
  • the formwork parts 116 , 118 have a rectangular shape
  • the formwork part 120 has the shape of a semicircular ring having two extensions 142 which point downward in FIGS. 35 to 38
  • the formwork parts 122 , 124 have the shape of a plate which is curved in an arc shape over approximately 80° in its upper portion (in order to form slightly less than half of the second end face 16 of the block 2 ) and is flat in its lower portion (in order to form part of a wall surface side 18 or 20 of the block 2 ).
  • the formwork parts 126 , 128 have the shape of a flat plate (for forming the remaining parts of the wall surface sides 18 and 20 of the block 2 and for forming the outer surfaces 62 of the two fins 60 of the block 2 ).
  • the formwork part 130 has a shape for forming the first end face 14 together with the inner surfaces 70 of the two fins 60 of the block 2 .
  • the formwork part 132 has the shape of a bowl that is halved in its central axis plane having an outwardly protruding rim
  • the formwork part 136 has an identical shape, although with two extensions 144 of the rim projecting downward in FIGS.
  • the formwork part 134 has the shape of a channel having two outwardly protruding rim portions. All the above-mentioned formwork parts are made of plastics material and are provided with reinforcing ribs in regions that do not face the cavity of the formwork to be filled with concrete.
  • the above-mentioned formwork parts are closely assembled for use, as shown in FIGS. 37 and 38 .
  • the formwork parts 114 , 116 , 118 , 120 , 132 , 134 , 136 have grooves 150 which edge regions of the formwork parts 122 , 124 , 126 , 128 , 130 enter in a form-fitting manner.
  • the formwork parts 122 , 124 , 126 , 128 , 130 have, at the edges thereof which are adjacent to another formwork part in each case, closed holes 152 or holes that are open on one side, so that connecting screws can be fitted there.
  • the closely assembled formwork parts 114 , 116 , 118 , 120 delimit an opening 154 , which roughly speaking has the shape of a slot with semicircular ends.
  • the bowl bottoms 156 of the formwork parts 132 , 136 and the channel bottom 158 of the formwork part 134 extend into this opening 154 in order to form the passage 52 in this way.
  • the formwork parts which are closely assembled in the manner described, are assembled between two outer pressure plates 160 in the manner of a sandwich, by a central tension rod 162 being attached.
  • the tension rod 162 is a metal rod having an external thread in each end region. It extends at a right angle to the plates 160 and passes through an opening 164 in the channel bottom 158 of the formwork part 134 . Nuts 166 are screwed onto the two ends of the tension rod 162 , such that the tension rod 162 tightens the entire sandwich described.
  • the filling opening 112 for concrete can be seen at the top of FIGS. 37 and 38 .
  • the formwork 110 is filled with concrete in the position shown in FIGS. 37 and 38 .
  • a block 2 having only one fin 60 can be produced, and by installing both insertion parts 138 and 140 , a block 2 completely without fins 60 can be produced, as shown in FIGS. 1 to 3 .
  • a filling opening would be provided on each of the extensions 142 , 144 that form the upwardly protruding fins 60 of the block 2 .

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US20230313525A1 (en) * 2022-03-29 2023-10-05 Newstone Group Concrete Products Ltd. Wall Block
WO2023249504A1 (en) * 2022-06-14 2023-12-28 Breaz Laureniu Dumitru Modular building elements
WO2024158693A1 (en) * 2023-01-23 2024-08-02 Anchor Wall Systems Limited Self-aligning wall block

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DE102018125548A1 (de) 2018-10-15 2020-04-16 Start Somewhere gemeinnützige GmbH Mauerblock
CN112160451B (zh) * 2020-10-30 2024-06-18 清华大学 模块化翻转墙体及其使用方法

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US12054941B2 (en) 2024-08-06
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ZA202102378B (en) 2022-12-21
MA53906A (fr) 2022-01-19
EP3867455A1 (de) 2021-08-25
WO2020078878A1 (de) 2020-04-23
BR112021007000A2 (pt) 2021-07-20

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